More problems, need help again

[big A]

So here is the newest problem. At any given time my scoot will shut completely down without warning. No specific range of speed, rpms, or bumps in the road. Bike loses complete power for a few seconds, backfires then starts running again. I thought carb at first but don't think it's a fuel problem cause it doesn't spit and sputter like running out of gas. Just shuts down like turning the key off. Battery cables are clean and very tight. Every connector that I've found has been lubbed up and connected tightly. This only happens about every 20 miles or so. Still have ehc but everything else is operating perfectly. I have noticed that the circuit breaker was tripped again(black button in the out position). I have found it tripped one other time about a month ago. I am assuming that when the button is out, it is tripped. I would think that if it was tripped the bike would not run at all. Any suggestions. Thanks all for the help, once again.

 

[Pops]

Sounds like the EHC Gremlins to me.....:angry:

 

[woodbutcher]

don't know whether or not you have already tried this, but, is the vent working in your gas cap??

 

[BigDogBro1]

When did you discover the circuit breaker button was popped out? Was it after the bike died?

Not sure on a 2004, but is that CB in-line with the regulator to the battery? Could the battery be running down too low that the EHC quits working if the breaker pops?

My thoughts!

 

[chacha]

Lots of "Could bes" here;

- Wire grounding ignition (cam sensor, coil, kill switch, tach line - this was a problem later fixed in the design)
- cam sensor gone bad -- site search will give you the story on that
- ECH -- but not the most likely cause....is your headlight low/high beam OK?
- ignition switch going bad

things to try.....

 

[RADAMS445]

don't know whether or not you have already tried this, but, is the vent working in your gas cap??

This haunted me for awhile too Tom.:up:

 

[Little-Boo]

The first thing I would do is check the ignition switch by starting the bike, then wiggling the key to see if it shuts off. If it does then that is your problem. Next I would get rid of the Circuit breaker. Get a 3/8 distribution post attach all wires to it and run a 40 amp fuse from the post to the Battery. Check the wires running from the CB to the VR to make sure they are not cut some where and are tripping you Circuit breaker. There are several posts on here as to how to check you VR to make sure it is not over charging and causing problems. FYI the VR and the 40 Amp fuse fix were recalls on these Bikes many moons ago. If you still have the CB on there maybe you missed the recall. Hope that help some.


Carlos :2thumbs:

 

[rwill20]

I had the same problem,it turned out that the eyelet connector on the positive side on the battery was corroded where it was connected to the wire.It was good and tight on the battery so it was a booger to find.Hope this helps.It was the small red wire,it think it powers the ehc.

 

[N8KAM]

The first thing I would do is check the ignition switch by starting the bike, then wiggling the key to see if it shuts off. If it does then that is your problem. Next I would get rid of the Circuit breaker. Get a 3/8 distribution post attach all wires to it and run a 40 amp fuse from the post to the Battery. Check the wires running from the CB to the VR to make sure they are not cut some where and are tripping you Circuit breaker. There are several posts on here as to how to check you VR to make sure it is not over charging and causing problems. FYI the VR and the 40 Amp fuse fix were recalls on these Bikes many moons ago. If you still have the CB on there maybe you missed the recall. Hope that help some.


Carlos :2thumbs:

This is where i would start...... common problem.

 

[mobsta]

My 04 did the same thing.Found a common poblem to be the rt side hand control pc board.I believe the circut breaker is inline with the battery so I would think that will shut down the charging system.Also a few guys have added the cruise mate if you have done this you could have metal shavings in the rt side hand control shorting the pc board.just something to look at good luck

 

[big A]

update

removed the vent plug from the gas cap. i will now replace the CB with a 40 amp fuse. I dont think it is a fuel issue cause the scoot doesnt bog down or spit and sputter like it is running out of gas. It shuts down like turning off the ignition. I have noticed that the tach lights go out. Havent paid attention to other lights to see if they are still on. Usually preoccupied with getting out of highway traffic. Will get out 2day and see what happens. In ref to the CB, i noticed that it was tripped after i pulled it into the garage several hours after i rode in. I would think that if it was tripped the bike wouldnt run at all. Thanks folks

 

[bigdogtech01]

removed the vent plug from the gas cap. i will now replace the CB with a 40 amp fuse. I dont think it is a fuel issue cause the scoot doesnt bog down or spit and sputter like it is running out of gas. It shuts down like turning off the ignition. I have noticed that the tach lights go out. Havent paid attention to other lights to see if they are still on. Usually preoccupied with getting out of highway traffic. Will get out 2day and see what happens. In ref to the CB, i noticed that it was tripped after i pulled it into the garage several hours after i rode in. I would think that if it was tripped the bike wouldnt run at all. Thanks folks

Gas cap vent is a good thought, but probably not the problem ( good to remove it anyhow before it becomes a problem ) If the bike shut off and then started again, it sounds like an ignition problem... such as Ignition, Coil, Ignition Switch. Yours has the pickup on the cam cover side correct? That pickup could be going bad. With heat it might fail. You can sometimes test it with a heat gun with the bike at idle, but be careful you don't melt anything while doing this test. Good luck, hope you find your problem.

 

[big A]

Update

Removed gas cap vent and CB. Drove scoot 10 miles out, got something to eat(turn scoot off). Then 10 miles back home with no problems. Might not have been far enough to let the prob happen again. Will drive further within next few days. Thanks again folks

 

[1ezrider]

I have an '07 K9 and it acted very similar (1)ONE time! on my way to work early in the morning, first time riding my new toy to work to show it off. about every 1/4 mile it would just die like i had turned the key off! let it sit for a minute or two, start right back up, run about another 1/4 mile more or less, then die again! finally one time while i was going down the road when it died i tried pushing the 'run' button, it backfired and kept running, this led me to believe the problem was probably in that switch, i hear there is a "hand control PC board"? this was 8 months ago, never has done it since, but then it starts when it wants to also, going to try the "wiggle the key switch trick" but personally I'm betting on the "hand control PC board" best wishes with yours, keep us posted,,, I'm also going to get rid of the damn EHC as soon as i can!